Self-sealing fastener and method of use

ABSTRACT

A self-sealing fastener for reducing leaks between the self-sealing fastener and a substrate. The self-sealing fastener includes a shank that extends longitudinally between a first end and a second end. The shank has an outer surface. The self-sealing fastener also includes a head that extends radially outwardly from the first end of the shank. The head has an underside surface that is adjacent to the first end of the shank and a topside surface opposite the underside surface. A mastic sealant is disposed on at least one of the outer surface of the shank and the underside surface of the head to provide a water-tight seal between the self-sealing fastener and the substrate after the self-sealing fastener is installed in the substrate.

CROSS REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional Application No.62/434,527, filed on Dec. 15, 2016. The entire disclosure of theapplication referenced above is incorporated herein by reference.

FIELD

The present disclosure generally relates to fasteners such as nails,screws, and bolts and more specifically to self-sealing fasteners andmethods for installing self-sealing fasteners.

BACKGROUND

This section provides background information related to the presentdisclosure which is not necessarily prior art.

In the construction industry, wood is often secured and held togetherusing fasteners such as nails, screws, and bolts. For example, nails,screws, and bolts are typically used in roofing construction and woodframe buildings. The purpose of the fastener is to penetrate a firstwood substrate and enter a second wood substrate to hold the first woodsubstrate to the second wood substrate. The penetration of the fastenerinto and through the first and second wood substrates creates apotential leak point for water.

Over time, the wood substrates will be exposed to environmentalconditions, which result in changes to the fibers of the wood substrate.Long-term environmental exposure to freeze and thaw and heat and colddries out the wood fibers such that the wood effectively contracts awayfrom the fasteners holding the substrates together. Repeated thermalvariation cycles of environmental exposure also decreases the strengthof wood substrates. In addition, exposure to wind, storms, and even thesettling of the wood construction itself can reduce the fastener'sability to maintain secure attachment between the wood substrates.

For these reasons, fasteners of wood substrates often become loose overtime and are easily dislodged during weather events such as hurricanesand/or tornadic storms. If the fasteners completely lose their abilityto maintain secure attachment between wood substrates, then failure ofthe structure can occur. However, even if the fasteners manage tomaintain a secure attachment between wood substrates during a weatherevent, leaks can occur because weather events often include rain alongwith wind. The wind often removes coverings such as shingles, felt rolllayers, and siding. Once these outer coverings are removed by the wind,the head of the fastener becomes directly exposed to environmentalelements and conditions. Due to the contraction of the wood substrateover time, water leakage can seep under the head of the fastener anddown the shank of the fastener and into the structure causing damage.

Fasteners are the first line of defense for wood framed structures.However, the main structure of a building is often framed with more ofan emphasis on speed than on quality because framing contractors almostalways frame by price per square foot. Because of this, the fastercontractors frame, the more money they make. Thus, the primary frame ofthe structure is often subject to inferior construction techniques dueto a hurried pace of construction. For example, in many instances,fasteners are improperly installed where the tip of the fastener and/ora portion of the shank of the fastener is exposed and extends out of thesecond wood substrate. The exposed tip and/or shank of the fastener is apotential problem on many levels. The exposed tip and/or shank of thefastener may be due to an errant location of the fastener by theinstaller. The exposed tip and/or shank of the fastener can be caused bythe fastener traveling off line during installation due to the grain ofthe wood substrate. The exposed tip and/or shank of the fastener canalso be from the use of a fastener that was excessively long to startwith. Regardless of the reason, the potential for leaks increases whenthe tip and/or shank of the fastener is left exposed. If structures areto be improved during the building process, there needs to beimprovements in materials and fasteners to compensate for the hurriedpace of construction at the expense of proper fastener applicationtechniques.

SUMMARY

This section provides a general summary of the disclosure and is not acomprehensive disclosure of its full scope or all of its features.

In accordance with one aspect of the subject disclosure, a self-sealingfastener is provided to reduce leaks between the fastener and asubstrate. The self-sealing fastener includes a shank that extendslongitudinally between a first end and a second end. The shank has anouter surface. The self-sealing fastener also includes a head thatextends radially outwardly from the first end of the shank. The head hasan underside surface that is adjacent to the first end of the shank anda topside surface opposite the underside surface. A mastic sealant isdisposed on at least one of the outer surface of the shank and theunderside surface of the head.

In accordance with another aspect of the subject disclosure, the head ofthe self-sealing fastener extends radially outwardly from the first endof the shank to an outer rim. The underside surface of the head includesa concave surface defined by an annular trough and a flat radial surfacepositioned radially between the concave surface and the outer rim. Themastic sealant is disposed on the outer surface of the shank adjacent tothe first end at a first thickness. The mastic sealant is disposed onthe concave surface of the underside surface of the head at a secondthickness. Finally, the mastic sealant is disposed on the flat radialsurface of the underside surface of the head at a third thickness. Thefirst, second, and third thicknesses of the mastic sealant may bedifferent or equal to one another depending upon the application.Advantageously, the mastic sealant provides a water-tight seal betweenthe self-sealing fastener and the substrate after the self-sealingfastener is installed in the substrate.

In accordance with another aspect of the subject disclosure, a method ofinstalling the self-sealing fastener is provided. The method includesthe steps of: applying a first layer of mastic sealant to at least oneof the shank and the underside surface of the head and applying a secondlayer of mastic sealant over the first layer of mastic sealant beforethe first layer of mastic sealant is fully cured. As a result of thisstep, the second layer of mastic sealant forms a protective skin overthe first layer of mastic sealant. The method also includes the step offorcing the shank of the self-sealing fastener into the substrate suchthat the second layer of mastic sealant ruptures as the second layer ofmastic sealant makes contact with the substrate. As a result of thisstep, the first layer of mastic sealant flows between the self-sealingfastener and the substrate to form a water-tight seal between theself-sealing fastener and the substrate.

BRIEF DESCRIPTION OF THE DRAWINGS

Other advantages of the present invention will be readily appreciated,as the same becomes better understood by reference to the followingdetailed description when considered in connection with the accompanyingdrawings wherein:

FIG. 1 is a side elevation view of an exemplary fastener constructed inaccordance with the subject disclosure where the fastener includes ahead and a smooth shank with a conical buttress;

FIG. 2 is a bottom perspective view of the exemplary fastenerillustrated in FIG. 1;

FIG. 3 is a side cross-sectional view of the exemplary fastenerillustrated in FIG. 1;

FIG. 4 is a side elevation view of the exemplary fastener illustrated inFIG. 1 where a mastic sealant has been applied to the conical buttressof the shank and an underside surface of the head;

FIG. 5 is a bottom perspective view of the exemplary fastenerillustrated in FIG. 4;

FIG. 6 is a side cross-sectional view of the exemplary fastenerillustrated in FIG. 4;

FIG. 7 is a side cross-sectional view of the exemplary fastenerillustrated in FIG. 1 where two layers of mastic sealant have beenapplied to the conical buttress of the shank and the underside surfaceof the head;

FIG. 8 is a side cross-sectional view of the exemplary fastenerillustrated in FIG. 7 where the fastener is shown extending throughfirst and second substrates;

FIG. 9 is a partial, side cross-sectional view of the exemplary fastenerillustrated in FIG. 1 where the fastener is shown installed in the firstsubstrate;

FIG. 10 is a partial, side cross-sectional view of the exemplaryfastener illustrated in FIG. 4 where the fastener is shown installed inthe first substrate;

FIG. 11 is a side elevation view of another exemplary fastenerconstructed in accordance with the subject disclosure where the fastenerincludes a head and a shank with ring-shaped projections and a conicalbuttress;

FIG. 12 is a bottom perspective view of the exemplary fastenerillustrated in FIG. 11;

FIG. 13 is a side elevation view of the exemplary fastener illustratedin FIG. 11 where the mastic sealant has been applied to the conicalbuttress of the shank and the underside surface of the head;

FIG. 14 is a bottom perspective view of the exemplary fastenerillustrated in FIG. 13;

FIG. 15 is a side elevation view of the exemplary fastener illustratedin FIG. 1 where the mastic sealant has been applied to a portion of theshank located between first and second ends of the shank;

FIG. 16 is a side elevation view of the exemplary fastener illustratedin FIG. 1 where the mastic sealant has been applied to the shank inthree separate rings located between the first and second ends of theshank;

FIG. 17 is a side elevation view of the exemplary fastener illustratedin FIG. 1 where the mastic sealant has been applied to the second end ofthe shank;

FIG. 18 is a side elevation view of the exemplary fastener illustratedin FIG. 1 where the mastic sealant has been applied to the undersidesurface of the head, to the first and second ends of the shank, and tothe shank in three separate rings located between the first and secondends of the shank;

FIG. 19 is a side elevation view of the exemplary fastener illustratedin FIG. 11 where the mastic sealant has been applied to a portion of theshank located between the first and second ends of the shank;

FIG. 20 is a side elevation view of the exemplary fastener illustratedin FIG. 11 where the mastic sealant has been applied to the shank inthree separate rings located between the first and second ends of theshank;

FIG. 21 is a side elevation view of the exemplary fastener illustratedin FIG. 11 where the mastic sealant has been applied to the second endof shank;

FIG. 22 is a side elevation view of the exemplary fastener illustratedin FIG. 11 where the mastic sealant has been applied to the undersidesurface of the head, to the first and second ends of the shank, and tothe shank in three separate rings located between the first and secondends of the shank;

FIG. 23 is a side elevation view of an exemplary fastener constructed inaccordance with the subject disclosure where the fastener includes ahead and a smooth shank;

FIG. 24 is a side elevation view of the exemplary fastener illustratedin FIG. 23 where the mastic sealant has been applied to the first end ofthe shank and the underside surface of the head;

FIG. 25 is a side elevation view of the exemplary fastener illustratedin FIG. 23 where the mastic sealant has been applied to a portion of theshank located between the first and second ends of the shank;

FIG. 26 is a side elevation view of the exemplary fastener illustratedin FIG. 23 where the mastic sealant has been applied to the shank inthree separate rings located between the first and second ends of theshank;

FIG. 27 is a side elevation view of the exemplary fastener illustratedin FIG. 23 where the mastic sealant has been applied to the second endof shank;

FIG. 28 is a side elevation view of the exemplary fastener illustratedin FIG. 23 where the mastic sealant has been applied to the undersidesurface of the head, to the first and second ends of the shank, and tothe shank in three separate rings located between the first and secondends of the shank;

FIG. 29 is a side elevation view of the exemplary fastener illustratedin FIG. 4 where a washer has been slid over the shank;

FIG. 30 is a top perspective view of the washer illustrated in FIG. 29where the mastic sealant that has been applied to a top surface of thewasher is shown; and

FIG. 31 is a bottom perspective view of the exemplary fastener andwasher illustrated in FIG. 29 where the mastic sealant that has beenapplied to a bottom surface of the washer, to the conical buttress ofthe shank, and to the underside of the head is shown.

DETAILED DESCRIPTION

Referring to the Figures, wherein like numerals indicate correspondingparts throughout the several views, a self-sealing fastener 1 isillustrated.

Example embodiments are provided so that this disclosure will bethorough, and will fully convey the scope to those who are skilled inthe art. Numerous specific details are set forth such as examples ofspecific components, devices, and methods, to provide a thoroughunderstanding of embodiments of the present disclosure. It will beapparent to those skilled in the art that specific details need not beemployed, that example embodiments may be embodied in many differentforms and that neither should be construed to limit the scope of thedisclosure. In some example embodiments, well-known processes,well-known device structures, and well-known technologies are notdescribed in detail.

The terminology used herein is for the purpose of describing particularexample embodiments only and is not intended to be limiting. As usedherein, the singular forms “a,” “an,” and “the” may be intended toinclude the plural forms as well, unless the context clearly indicatesotherwise. The terms “comprises,” “comprising,” “including,” and“having,” are inclusive and therefore specify the presence of statedfeatures, integers, steps, operations, elements, and/or components, butdo not preclude the presence or addition of one or more other features,integers, steps, operations, elements, components, and/or groupsthereof. The method steps, processes, and operations described hereinare not to be construed as necessarily requiring their performance inthe particular order discussed or illustrated, unless specificallyidentified as an order of performance. It is also to be understood thatadditional or alternative steps may be employed.

When an element or layer is referred to as being “on,” “engaged to,”“connected to,” or “coupled to” another element or layer, it may bedirectly on, engaged, connected or coupled to the other element orlayer, or intervening elements or layers may be present. In contrast,when an element is referred to as being “directly on,” “directly engagedto,” “directly connected to,” or “directly coupled to” another elementor layer, there may be no intervening elements or layers present. Otherwords used to describe the relationship between elements should beinterpreted in a like fashion (e.g., “between” versus “directlybetween,” “adjacent” versus “directly adjacent,” etc.). As used herein,the term “and/or” includes any and all combinations of one or more ofthe associated listed items.

Although the terms first, second, third, etc. may be used herein todescribe various elements, components, regions, layers and/or sections,these elements, components, regions, layers and/or sections should notbe limited by these terms. These terms may be only used to distinguishone element, component, region, layer or section from another region,layer or section. Terms such as “first,” “second,” and other numericalterms when used herein do not imply a sequence or order unless clearlyindicated by the context. Thus, a first element, component, region,layer or section discussed below could be termed a second element,component, region, layer or section without departing from the teachingsof the example embodiments.

Spatially relative terms, such as “inner,” “outer,” “beneath,” “below,”“lower,” “above,” “upper,” and the like, may be used herein for ease ofdescription to describe one element or feature's relationship to anotherelement(s) or feature(s) as illustrated in the figures. Spatiallyrelative terms may be intended to encompass different orientations ofthe device in use or operation in addition to the orientation depictedin the figures. For example, if the device in the figures is turnedover, elements described as “below” or “beneath” other elements orfeatures would then be oriented “above” the other elements or features.Thus, the example term “below” can encompass both an orientation ofabove and below. The device may be otherwise oriented (rotated 90degrees or at other orientations) and the spatially relative descriptorsused herein interpreted accordingly.

Referring to FIGS. 1-3, an exemplary fastener 1 is shown comprised of ashank 2 and a head 5. The shank 2 is juxtaposed between a conicalbuttress 4 and a point 3. The shank 2 extends longitudinally between afirst end 31 and a second end 32. The conical buttress 4 is located andthe first end 31 of the shank 2 and the point 3 is located at the secondend 32 of the shank 2. The shank 2 has an outer surface 33, which issmooth and cylindrically shaped in the illustrated embodiment shown inFIGS. 1-3. The head 5 extends radially outwardly from the first end 31of the shank 2 to an outer rim 10. The head 5 has an underside surface34 that is adjacent to the first end 31 of the shank 2. The head 5 alsoincludes a topside surface 35 opposite the underside surface 34. Theunderside surface 34 of the head 5 has a concave surface 7 that isdefined by a trough 9 that extends annularly about the first end 31 ofthe shank 2. The underside surface 34 of the head 5 also has a flatradial surface 8 that is positioned radially between the concave surface7 and the outer rim 10. The trough 9 on the underside surface 34 of thehead 5 extends radially from the conical buttress 4 to the flat radialsurface 8. The flat radial surface 8 is oriented relatively transverseto the shank 2 and is provided toward the outer rim 10 of the head 5.Outer rim 10 is relatively parallel to the shank 2. There is atransition point 6 where the conical buttress 4 meets the outer surface33 of the shank 2. The transition point 6 can be a radius, chamfer, orsimilar shape between the outer surface 33 of the shank 2 and theconical buttress 4. The shank 2 has a shank diameter D. The shankdiameter D progressively increases along the conical buttress 4 movingfrom the transition point 6 to the underside surface 34 of the head 5.

The fastener 1 may be fabricated by drawing wire down to a selected feedstock wire diameter. Once a desired feed stock wire diameter isachieved, the wire feed stock is fed into a header machine that clampsthe wire in a die where a forming operation occurs. The primary formingoperation may include, but is not limited to, cutting the wire feedstock to a specific length according to the application requirements.The primary forming operation may also include shaping the point 3 onthe second end 32 of the fastener 1. The primary forming operation mayalso include shaping the head 5 on the first end 31 of the fastener 1.

The primary forming operations previously listed may or may not happensimultaneously. Some operations may require a multi-step formingprocess. Usually the complexity of the shape and/or the size of thefastener 1 will dictate how many primary forming operations arerequired. After the primary forming operations are complete, additionalsecondary forming operations may be required. Some of the types ofsecondary forming operations include, but are not limited to, formingring-like structures on the outer surface 33 of the shank 2, forming abreak-a-way groove on the shank 2, forming thread-like structures on theouter surface 33 of the shank 2, applying adhesive to the fastener 1,adding specialized markings/identifications to the fastener 1, andcollating fasteners 1 into coils and/or sticks.

Referring to FIGS. 4-6, a mastic sealant 11 is disposed on the outersurface of the shank and the underside surface of the head. Morespecifically, the mastic sealant 11 is applied to the conical buttress 4of the shank 2, the concave surface 7 of the head 5, and the flat radialsurface 8 of the head 5. The mastic sealant 11 provides a water-tightseal after installation of the self-sealing fastener 1. Little or nomastic sealant 11 is applied past the transition point 6 on the shank 2.The mastic sealant 11 is shown in FIG. 4 as dotted lines. However, itshould be appreciated that in this preferred embodiment, the masticsealant 11 covers the entire circumference of the portions and surfacesof the fastener 1 adjacent the dotted lines. This representation will beconsistent throughout the figures of this disclosure. Similarly,portions and surfaces of the fastener 1 shown in FIG. 5 appear to becovered with mastic sealant 11 that is depicted as being scattered,splotchy, or applied as a pattern of dots. Although the mastic sealant11 could be applied as in pattern of dots, lines, or other shapes, themastic sealant 11 in the preferred embodiment is applied to cover theentire portions and surfaces of the fastener 1 where the pattern fill isdepicted. This representation will be consistent throughout the figuresof this disclosure.

As will be explained below, exemplary embodiments include applying themastic sealant 11 to the underside surface 34 of the head 5, to variousportions of the shank 2, and/or to the point 3 of the fastener 1. Themastic sealant 11 can also be applied to fasteners 1, which also mayfeature additional adhesive coatings.

Referring to FIGS. 7 and 8, the mastic sealant 11 is applied in a firstsealant layer 12 and the second sealant layer 13. The first sealantlayer 12 is applied to the underside surface 34 of the head 5 and to theconical buttress 4. After an appropriate drying time, the second sealantlayer 13 is applied over the first sealant layer 12. The drying time ofthe mastic sealant 11 will vary according to the formulation of themastic sealant 11. By way of example and without limitation, anappropriate drying time for the second sealant layer 13 may be as shortas one hour and as long as twenty-four hours. Therefore, some masticsealants 11 dry in a shorter time than other mastic sealants 11. Thefirst sealant layer 12 will need a certain amount of drying time beforethe second sealant layer 13 is applied. However, the first sealant layer12 need not be fully dried before the second sealant layer 13 isapplied. The first sealant layer 12 needs to only partially cure beforethe second sealant layer 13 is applied because the second sealant layer13 will provide a protective skin over the first sealant layer 12,preventing the mastic sealant 11 in the first sealant layer 12 fromcompletely drying or curing. A preferred partial curing time for thefirst sealant layer 12 is 5 to 40 percent of the time required to fullydry and cure the mastic sealant 11. The mastic sealant 11 in the firstsealant layer 12 may develop a thin skin cure in as little as 5-10minutes, at which point the second sealant layer 13 can be applied. Thesecond sealant layer 13 will therefore be fully dried and cured whilethe first sealant layer 12 remains partially cured until the fastener 1is installed in the substrate 14. The second sealant layer 13 is exposedto atmosphere and/or to low-level curing methods. As a result, the firstsealant layer 12 is disposed on the concave surface 7 of the head 5, theflat radial surface 8 of the head 5, and the conical buttress 4 of theshank 2. The second sealant layer 13 is applied to the same surfaces asthe first sealant layer 12, essentially covering the first sealant layer12.

The first sealant layer 12 and the second sealant layer 13 are shown inFIG. 7 as dotted lines. However, the first and second sealant layers 12,13 cover the entire circumference of the portions and surfaces of thefastener 1 adjacent to the dotted lines. This representation will beconsistent throughout the figures of this disclosure. The second sealantlayer 13 shields and protects the first sealant layer 12 from exposureto atmosphere and/or environmental conditions which would otherwisecontinue to cure the first sealant layer 12. The length of time betweenapplication of the first sealant layer 12 and the second sealant layer13 is relatively short in a controlled manufacturing facility andproduction line system. However, the length of time between when thecompleted fastener 1 with the first and second sealant layers 12, 13 isshipped to end users and when the fastener 1 is installed is arelatively long time. Therefore, the second sealant layer 13 ensuresthat the mastic sealant 11 in the first sealant layer 12 remainsresilient and pliable during the relatively lengthy period betweenfabrication and installation. Prior to installing the fastener 1 intoone or more substrates 14, 15, the “cure state” and “viscosity” of themastic sealant 11 in the second sealant layer 13 is greater than the“cure state” and “viscosity” of the mastic sealant 11 in the firstsealant layer 12. In other words, the mastic sealant 11 in the firstsealant layer 12 has a relatively lower viscosity and/or cure state,while the mastic sealant 11 in the second sealant layer 13 has arelatively higher state of cure and/or a relatively higher viscosity.For example, and without limitation, the mastic sealant 11 may besilicone based. The viscosity of silicone based mastic sealants 11varies with the level of polymerization. The greater the level ofpolymerization of the mastic sealant 11, the higher the molecular weightof the mastic sealant 11. The higher the molecular weight of the masticsealant 11, the longer the polymer chain. The longer the polymer chain,the higher the relatively viscosity of the mastic sealant 11. The higherthe relative viscosity of the mastic sealant 11, the more slowly themastic sealant 11 will flow. The viscosity of mastic sealants may varyfrom highly fluid mastic sealants with a viscosity of 0.65 centistokes(which is thinner than water) to very thick mastic sealants with aviscosity of more than 20,000,000 centistokes (which is thicker thanchewing gum). By way of example and without limitation, the firstsealant layer 12 may have a viscosity in the range of 10 to 200centistokes while the second sealant layer 13 may have a viscosity inthe range of 200 to 20,000,000 centistokes. While the specific range ofviscosity for the first sealant layer 12 and the second sealant layer 13may vary, it is important for the relative viscosity of the firstsealant layer 12 to be is less than the relative viscosity of the secondsealant layer 13.

The second sealant layer 13 may be applied as a thin layer, which mayhave a thickness that equals 25 to 50 percent of the thickness of thefirst sealant layer 12. As a result, the second sealant layer 13 forms athin protective skin over the lesser cured mastic sealant 11 in thefirst sealant layer 12, which is underneath the second sealant layer 13and next to the fastener 1. As shown in FIG. 8, when the fastener 1 isinstalled into substrates 14, 15, the thin skin of the second sealantlayer 13 ruptures, allowing the lesser cured mastic sealant 11 in thefirst sealant layer 12 to flow into gap 18 and against the substrate 14forming both a bond and a flexible seal.

A method of installing the self-sealing fastener 1 shown in FIGS. 7 and8 will now be described. The method includes the step of applying afirst layer 12 of mastic sealant 11 to at least one of the shank 2 ofthe self-sealing fastener 1 and the underside surface 34 of the head 5of the self-sealing fastener 1. The method continues with the step ofapplying a second layer 13 of mastic sealant 11 over the first layer 12of mastic sealant 11 before the first layer 12 of mastic sealant 11 isfully cured such that the second layer 13 of mastic sealant 11 forms aprotective skin over the first layer 12 of mastic sealant 11. The methodthen continues with the step of forcing the shank 2 of the self-sealingfastener 1 into the substrate 14 such that the second layer 13 of masticsealant 11 ruptures as the second layer 13 of mastic sealant 11 makescontact with the substrate 14. As a result of the second layer 13 ofmastic sealant 11 rupturing, the first layer 12 of mastic sealant 11 isallowed to flow between the self-sealing fastener 1 and the substrate 14and form a water-tight seal.

Referring to FIGS. 9 and 10, the fastener 1 is shown installed in asubstrate 14. Over time, the substrate 14 is exposed to environmentalconditions which result in changes to the wood fibers of the substrate14. The long term environmental exposure to freeze and thaw and heat andcold cycles dries out the wood fibers such that the substrate 14effectively contracts away from the fastener 1, creating a gap 18. As aresult, surface 20 of the substrate 14 will not be in intimate contactwith the conical buttress 4 of the fastener 1.

Like most all materials, wood has a characteristic property of thermalconductivity. The thermal conductivity of wood is relatively low becausethe innate porosity of wood is relatively high. Therefore, the thermalconductivity of wood decreases proportionally as the density of the wooddecreases. Thermal conductivity of wood increases proportionally asmoisture in the wood increases. These relationships also mean that asthe temperature of a wood decreases, due to the environmental conditionsto which it is exposed, the strength of the wood will proportionallyincrease. Repeated thermal variation cycles of environmental exposuredecrease the strength of wood in the substrate 14.

Thermal conductivity of materials can also be evaluated by thecoefficient of thermal expansion for a given material. For example, thecoefficient of thermal expansion for wood varies depending on the typeof wood and varies with the wood grain orientation. The scope of thisdisclosure does not require a detailed differentiation of wood types orgrain orientations. Therefore, the coefficient of thermal expansion formost substrates made of wood is approximately 0.0000028-0.0000030 inchesper degree Fahrenheit. This means the entirety of the substrate 14expands and contracts proportionally with environmental temperaturechanges according to this relationship.

In similar fashion, the fastener 1 also thermally expands and contractsin proportion to the same environmental conditions to which thesubstrate 14 is exposed. In the preferred embodiment, the fastener 1 isfabricated from steel. The coefficient of thermal expansion for steelvaries depending upon the specific type and grade of steel. The scope ofthis disclosure does not require a detailed differentiation of steeltypes or grades. Therefore, the coefficient of thermal expansion formost steel is approximately 0.0000063-0.0000070 inches per degreeFahrenheit. This means the entirety of the fastener 1 expands andcontracts proportionally with environmental temperature changesaccording to this relationship.

Most notable in comparing the coefficient of thermal expansion for thefastener 1 to that of the substrate 14 is that the fastener 1 expandsalmost twice as much per degree Fahrenheit as the substrate 14 whenexposed to the same environmental conditions. Since the fastener 1 has ahigher density and hardness than the substrate 14, the inside holediameter surface 20 of the substrate 14 will be increased andeffectively swedged beyond its initial size. When thermal environmentalconditions reverse, the fastener 1 will contract in size at a rate twicethat of the substrate 14. However, the relative inelastic nature of thesubstrate 14 means that the increased size of the swedged hole willremain predominately enlarged relative to the outer surface 33 of theshank 2 creating a gap 18 between the inside hole diameter surface 20and the outer surface 33 of the shank 2. This difference in diametersbetween the shank 2 of the fastener 1 and the inside hole diametersurface 20 of the substrate 14 creates a potential leakage path forwater ingress.

Similar loosening and/or leakage paths occur for the same reasonsbetween the underside surface 34 of the head 5 of the fastener 1 and thesubstrate 14. As the head 5 of the fastener 1 is embedded relativelyflush into the substrate 14, a depression 17 is formed and there is aninitial intimate surface contact between the head 5 of the fastener 1and the substrate 14. However, over time, the coefficient of thermalexpansion differences between the fastener 1 and the substrate 14 resultin a less intimate surface contact, which allows an opportunity forwater leakage between the underside surface 34 of the head 5 of thefastener 1 and the substrate 14. For these reasons, the fastener 1 maybecome loose over time and may become easily dislodged from thesubstrate 14 during weather events such as hurricanes and/or tornadicstorms. If the fastener 1 completely loses its ability to maintain asecure position in the substrate, then the holding power of the fastener1 is compromised.

Even if the fastener 1 maintains a secure position in substrate 14during a weather event, weather events often include much rain alongwith the wind effects. The wind effects often remove coverings such asshingles, felt roll layers, siding, and the like. Once these outercoverings are removed by wind, the head 5 of the fastener 1 becomesdirectly exposed to environmental elements and conditions. Due to thecontraction of the substrate 14, water leakage can seep under the head 5of the fastener 1 and down the shank 2 of the fastener 1. This waterleakage can cause damage to the substrate 14 and surrounding structures.

For example, fasteners 1 used to hold roof sheathing are notorious formoving upward over time. Heat dries the sheathing and loosens thefasteners 1. This is a well-known concern. The head 5 of the fasteners 1allow water to “seep” in and leaks occur. If not detected, sheathingdeteriorates, insulation molds and sheet rock is damaged. In colderseasons, the environmental conditions will promote this water to freezeresulting in deterioration and splitting of the substrate 14. Inaddition, the fasteners 1 can rust.

As shown in FIG. 10, mastic sealant 11 forms an initial water tight sealbetween the fastener 1 and the substrate 14, which prevents waterleakage between the fastener 1 and the substrate 14. More specifically,the mastic sealant 11 flows into and fills gap portions 21, 22, 23, and24 during installation of the fastener 1 into the substrate 14. As thesubstrate 14 contracts and shrinks over time, the mastic sealant 11maintains a seal in the gap 18.

As wood contraction takes place over time, the fastener 1 is effectivelyin a looser position relative to the substrate 14 because of theexpansion and contraction of the fastener 1 and the substrate 14. Theslightly looser condition allows the substrate 14 and the fastener 1 tomove relative each other in very small increments. These smallincrements of relative movement are caused by environmental thermalexpansion of the wood of the substrate 14 relative to the thermalexpansion of the steel in the fastener 1. This thermal expansiondifference is reversed as the structure is exposed to cold conditions.However, the mastic sealant 11 remains resilient over time. As theincremental relative movements of the fastener 1 and the substrate 14occur, the mastic sealant 11 maintains the water tight seal between thefastener 1 and the substrate 14. In other words, when the relativeposition of the fastener 1 and the substrate 14 are at rest and notmoving, the water tight seal provided by the mastic sealant 11 isrelatively static. However, when there is relative incremental movementbetween the fastener 1 and the substrate 14, the water tight sealprovided by the mastic sealant 11 between the fastener 1 and thesubstrate 14 is relatively dynamic. The water tight seal is maintainedduring such relative incremental movements between the fastener 1 andthe substrate 14 due to the flexibility of the mastic sealant 11. Itshould be appreciated that while the above discussion focuses on asubstrate 14 made of wood and a fastener 1 made of steel, thesematerials are provided as examples and are not intended as limiting.

In addition to sealing potential leak paths between the fastener 1 andthe substrate 14, the mastic sealant 11 also provides other benefits.For example, the self-sealing fastener 1 has improved seismic/vibrationresistance over conventional fasteners because the mastic sealant 11bonds to the substrate 14. Additionally, the portions and surfaces ofthe fastener 1 that are coated with the mastic sealant 11 are protectedfrom the environment (e.g., moisture) and are therefore less prone torust, which extends the life of the fastener 1 beyond that ofconventional fasteners.

The mastic sealant 11 may be applied to the various portions andsurfaces of the fastener 1 with a uniform thickness. Alternatively, themastic sealant 11 may be applied at a greater thickness on some surfacesand at a lesser thickness on other surfaces of the fastener 1. Withreference to FIGS. 4-6 and 10, the mastic sealant 11 may be applied tothe conical buttress 4 at a first thickness, to the concave surface 7 ata second thickness, and to the flat radial surface 8 at a thirdthickness. In some industry specific applications, such asgeneral-purpose fasteners, the mastic sealant 11 is applied relativelyuniform where the first thickness of the mastic sealant 11 applied tothe conical buttress 4 equals the second thickness of the mastic sealant11 applied to the concave surface 7 and the second thickness of themastic sealant 11 applied to the concave surface 7 equals the thirdthickness of the mastic sealant 11 applied to the flat radial surface 8.The following expression set forth in Equation A below recites thecomparative thickness of the mastic sealant 11 on surfaces 4, 7, and 8using this application scenario:

Surface 4=Surface 7=Surface 8  Equation A:

In other industry specific applications, such as exposed constructionwith known water exposure, the mastic sealant 11 is applied deliberatelythicker on some surfaces compared to other surfaces. For example, themastic sealant 11 may be applied where the second thickness of themastic sealant 11 applied to the concave surface 7 is greater than thethird thickness of the mastic sealant 11 applied to the flat radialsurface 8 and the third thickness of the mastic sealant 11 applied tothe flat radial surface 8 is greater than the first thickness of themastic sealant 11 applied to the conical buttress 4. The followingexpression set forth in Equation B below recites the comparativethickness of the mastic sealant 11 on surfaces 4, 7, and 8 using thisapplication scenario:

Surface 7>Surface 8>Surface 4  Equation B:

In still other industry specific applications, such as installationswhere the substrate 14 may contract or shrink excessively due to extremeenvironmental heat exposure, creating a contraction gap 18, it may bedesirable to have excess mastic sealant 11 applied on the conicalbuttress 4 so that as the fastener 1 is installed into the substrate 14,a wiping action forces the excess mastic sealant 11 upward toward theunderside surface 34 of the head 5 ensuring greater coverage on thesubstrate surface 20 adjacent to the conical buttress 4. For example,the mastic sealant 11 may be applied where the first thickness of themastic sealant 11 applied to the conical buttress 4 is greater than thesecond thickness of the mastic sealant 11 applied to the concave surface7 and the second thickness of the mastic sealant 11 applied to theconcave surface 7 is equal to the third thickness of the mastic sealant11 applied to the flat radial surface 8. The following expression setforth in Equation C below recites the comparative thickness of themastic sealant 11 on surfaces 4, 7, and 8 using this applicationscenario:

Surface 7=Surface 8<Surface 4  Equation C:

As shown by Equations A-C, the fastener 1 may have any one of multiplevariations of applied film thickness of the mastic sealant 11 providedto meet industry specific requirements. All variations of applied filmthickness may be provided using the same mastic sealant 11 and the sameapplication methods. Alternatively, different mastic sealants 11 and/ordifferent application methods may be used for the different surfaces ofthe fastener 1.

Application methods for applying the mastic sealant 11 include, but arenot limited to dipping, masking certain portions of the fastener 1 toprevent application, brushing, spraying, electrostatic spraying,transferring, silk screen, and other similar methods and techniques.Notwithstanding these examples, it should be appreciated that the scopeof this disclosure does not depend upon the method used to apply themastic sealant 11.

The mastic sealant 11 may be any one of several readily available masticsealants and/or mastic-like products, such as silicone based sealants,elastomer based sealants, coal tar and/or petroleum byproduct sealants,caulk-like sealants, epoxy sealants, and other similar products whichretain a relatively resilient characteristic over time.

Referring again to FIGS. 7 and 8, in some industry specificapplications, such as general-purpose fasteners, the first sealant layer12 may be applied to the fastener 1 at a relatively uniform thicknessacross the conical buttress 4, the concave surface 7, and the flatradial surface 8 of the fastener 1. The following expression set forthin Equation D below recites the comparative thickness of the firstsealant layer 12 on surfaces 4, 7, and 8 using this applicationscenario:

for the first sealant layer 12: Surface 4=Surface 7=Surface 8  EquationD

In other industry specific applications, such as exposed constructionwith known water exposure, the first sealant layer 12 may be appliedwhere the mastic sealant 11 is deliberately thicker on some surfaces andthinner on other surfaces of the fastener 1. For example, the firstsealant layer 12 may be applied where the mastic sealant 11 in the firstsealant layer 12 is thicker on the concave surface 7 of the head 5 thanit is on the flat radial surface 8 of the head 5 and where the masticsealant 11 in the first sealant layer 12 on the flat radial surface 8 ofthe head 5 is thicker than it is on the conical buttress 4. Thefollowing expression set forth in Equation E below recites thecomparative thickness of the first sealant layer 12 on surfaces 4, 7,and 8 using this application scenario:

for the first sealant layer 12: Surface 7>Surface 8>Surface 4  EquationE

In still other industry specific applications, such as installationswhere the substrate 14 may contract or shrink excessively due to extremeenvironmental heat exposure, creating a contraction gap 18, it may bedesirable to have excess mastic sealant 11 in the first sealant layer 12applied on the conical buttress 4 so that as fastener 1 is installedinto the substrate 14, a wiping action forces excess mastic sealant 11upward toward the underside surface 34 of the head 5. This ensuresgreater coverage of the mastic sealant 11 in the first sealant layer 12on the conical buttress 4. For example, the thickness of the masticsealant 11 in the first sealant layer 12 on the concave surface 7 andthe flat radial surface 8 may be equal, but less than the thickness ofthe mastic sealant 11 in the first sealant layer 12 on the conicalbuttress 4. The following expression set forth in Equation F belowrecites the comparative thickness of the first sealant layer 12 onsurfaces 4, 7, and 8 using this application scenario:

for the first sealant layer 12: Surface 7=Surface 8<Surface 4  EquationF

In some industry specific applications, such as general-purposefasteners, the second sealant layer 13 may be applied to the fastener 1at a relatively uniform thickness across the conical buttress 4, theconcave surface 7, and the flat radial surface 8 of the fastener 1. Thefollowing expression set forth in Equation G below recites thecomparative thickness of the second sealant layer 13 on surfaces 4, 7,and 8 using this application scenario:

for the second sealant layer 13: Surface 4=Surface 7=Surface 8  EquationG

In other industry specific applications, such as exposed constructionwith known water exposure, the second sealant layer 13 may be appliedwhere the mastic sealant 11 is deliberately thicker on some surfaces andthinner on other surfaces of the fastener 1. For example, the secondsealant layer 13 may be applied where the mastic sealant 11 in thesecond sealant layer 13 is thicker on the concave surface 7 of the head5 than it is on the flat radial surface 8 of the head 5 and where themastic sealant 11 in the second sealant layer 13 on the flat radialsurface 8 of the head 5 is thicker than it is on the conical buttress 4.The following expression set forth in Equation H below recites thecomparative thickness of the second sealant layer 13 on surfaces 4, 7,and 8 using this application scenario:

for the second sealant layer 13: Surface 7>Surface 8>Surface 4  EquationH

In still other industry specific applications, such as installationswhere the substrate 14 may contract or shrink excessively due to extremeenvironmental heat exposure, creating a contraction gap 18, it may bedesirable to have excess mastic sealant 11 in the second sealant layer13 applied to the conical buttress 4 so that as fastener 1 is installedinto the substrate 14, a wiping action forces excess mastic sealant 11upward toward the underside surface 34 of the head 5. This ensuresgreater coverage of the mastic sealant 11 in the second sealant layer 13on surfaces of the substrate 14 adjacent to the conical buttress 4. Forexample, the thickness of the mastic sealant 11 in the second sealantlayer 13 on the concave surface 7 and the flat radial surface 8 may beequal, but less than the thickness of the mastic sealant 11 in thesecond sealant layer 13 on the conical buttress 4. The followingexpression set forth in Equation I below recites the comparativethickness of the second sealant layer 13 on surfaces 4, 7, and 8 usingthis application scenario:

for the second sealant layer 13: Surface 7=Surface 8<Surface 4  EquationI

The first sealant layer 12 and the second sealant layer 13 may or maynot have the same type of mastic sealant 11. Any of the examples for themastic sealant 11 noted above may be used for the first and/or secondsealant layers 12, 13. Similarly, the first sealant layer 12 and thesecond sealant layer 13 may be applied using the same applicationprocess or different application processes. Any of the exemplaryapplication processes noted above may be used to apply the first and/orsecond sealant layers 12, 13 to the fastener 1. Furthermore, thethickness of the first sealant layer 12 may or may not be the same asthe thickness of the second sealant layer 13 at any given location onthe fastener 1. As noted above, the thickness of the second sealantlayer 13 may equal 25 percent to 50 percent of the thickness of thefirst sealant layer 12 at any given location on the fastener 1.

Still further, the relative state of cure of portions of the firstsealant layer 12 may or may not be as cured as equivalent portions ofthe second sealant layer 13. As noted above, the mastic sealant 11 inthe first sealant layer 12 may be in a lower state of cure relative tothe mastic sealant 11 in the second sealant layer 13 so that the secondsealant layer 13 can shield and protect the mastic sealant 11 in thefirst sealant layer 12. In such a configuration, the mastic sealant 11in the first sealant layer 12 flows out of its covered confinement whenthe second sealant layer 13 ruptures as the fastener 1 is installed intothe substrate 14 such that a relatively fresh application of masticsealant 11 from the first sealant layer 12 flows between the fastener 1and the substrate 14 to form a water tight seal.

Referring to FIGS. 11-14, the shank 2 of the fastener 1 may include asurface treatment such as a plurality of ring-shaped projections 25 thatextend annularly about the outer surface 33 of the shank 2. As shown inFIGS. 13 and 14, the mastic sealant 11 is applied to the conicalbuttress 4 of the shank 2, the concave surface 7 of the head 5, and theflat radial surface 8 of the head 5 in the illustrated embodiment.However, the application and/or locations of the mastic sealant 11 isnot necessarily dependent on whether the fastener 1 has a surfacetreatment on the shank 2.

Referring to FIGS. 15-22, the mastic sealant 11 may be applied todifferent locations of the fastener 1. For example, as shown in FIGS. 15and 19, the mastic sealant 11 may be applied along only a portion of theshank 2 that is located between the first and second ends 31, 32 of theshank 2. Alternatively, the mastic sealant 11 may be applied in threeannular strips or rings that are longitudinally spaced from one anotherbetween the first and second ends 31, 32 of the shank 2 (FIGS. 16 and20). As another alternative, the mastic sealant 11 may be applied tosecond end 32 of the shank 2 at a location adjacent to the point 3 ofthe fastener 1 (FIGS. 17 and 21). In an alternative embodiment shown inFIGS. 18 and 22, the mastic sealant 11 has been applied to the undersidesurface 34 of the head 5, to the conical buttress 4, to the second end32 of the shank 2, and to the outer surface 33 of the shank in threelongitudinally spaced rings located between the first and second ends31, 32 of the shank 2.

Referring to FIGS. 23-28, fastener 26 includes shank 2 and head 5.Fastener 26 does not include the conical buttress 4 of fastener 1.Instead, the shank 2 extends longitudinally between the concave surface7 of the head and the point 3 of the fastener 26. As shown in FIG. 9,the concave surface 7 of the head 5 is formed by trough 9, which extendsannularly about the first end 31 of the shank 2. The relatively flatradial surface 8 is oriented relatively transverse to the shank 2. Theflat radial surface 8 extends radially from the concave surface 7 to theouter rim 10 of the head 5.

Mastic sealant 11 is applied to the first end 31 of the shank 2 at afirst thickness, to the concave surface 7 of the head 5 at a secondthickness, and to the flat radial surface 8 of the head 5 at a thirdthickness. Although the mastic sealant 11 is shown in FIG. 24 as dottedlines, the mastic sealant 11 covers the entire circumference of theportions and surfaces of the fastener 26 adjacent to the dotted lines.This representation will be consistent throughout the figures of thisdisclosure.

In some industry specific applications, such as general-purposefasteners, the mastic sealant 11 may be applied to the fastener 26 in arelatively uniform thickness. In other words, the first thickness of themastic sealant 11 applied to the first end 31 of the shank 2, the secondthickness of the mastic sealant 11 applied to the concave surface 7 ofthe head 5, and the third thickness of the mastic sealant 11 applied tothe flat radial surface 8 of the head 5 are equal. The expression setforth in Equation J below recites the comparative thickness of themastic sealant 11 on surfaces 2, 7, and 8 using this applicationscenario:

Surface 2=Surface 7=Surface 8  Equation J:

In other industry specific applications, such as exposed constructionwith known water exposure, the mastic sealant 11 may be applied to bedeliberately thicker on some surfaces and thinner on other surfaces ofthe fastener 26. For example, the mastic sealant 11 may be thicker onthe concave surface 7 than it is on the flat radial surface 8 and themastic sealant 11 may be thicker on the flat radial surface 8 than it ison the first end of the shank 2. In other words, the second thickness ofthe mastic sealant 11 applied to the concave surface 7 of the head 5 isgreater than the third thickness of the mastic sealant 11 applied to theflat radial surface 8 of the head 5 and the third thickness of themastic sealant 11 applied to the flat radial surface 8 of the head 5 isgreater than the first thickness of the mastic sealant 11 applied to thefirst end 31 of the shank 2. The expression set forth in Equation Kbelow recites the comparative thickness of the mastic sealant 11 onsurfaces 2, 7, and 8 using this application scenario:

Surface 7>Surface 8>Surface 2  Equation K:

In an installation scenario in which fastener 26 is installed in thesubstrate 14 shown in FIG. 10, contraction and/or shrinkage may occurdue to extreme environmental heat exposure. If so, contraction gap 18will result. In such a scenario, it is desirable to have excess masticsealant 11 applied to the fastener 26 before it is installed into thesubstrate 14. A wiping action forces the excess mastic sealant 11 upwardtoward the underside surface 34 of the head 5. This ensures greatercoverage of the mastic sealant 11 on the substrate surface 20 adjacentto the shank 2. In such a scenario, the mastic sealant 11 may be thickeron the first end 31 of the shank 2 and thinner on the concave surface 7and the flat radial surface 8, which may have equal thicknesses of themastic sealant 11. In other words, the first thickness of the masticsealant 11 applied to the first end 31 of the shank 2 is greater thanthe second thickness of the mastic sealant 11 applied to the concavesurface 7 of the head 5 and the third thickness of the mastic sealant 11applied to the flat radial surface 8 of the head equals the secondthickness of the mastic sealant 11 applied to the concave surface 7 ofthe head 5. The expression set forth in Equation L below recites thecomparative thickness of the mastic sealant 11 using this applicationscenario:

Surface 7=Surface 8<Surface 2  Equation L:

The fastener 26 shown in FIGS. 23-28 may have any one of multiplevariations of applied thicknesses of the mastic sealant 11 provided tomeet industry specific requirements. All such variations may be providedusing the same or different mastic sealant 11 and the same or differentapplication methods. Application methods suitable for applying themastic sealant 11 to the fastener 26 include, but are not limited todipping, masking certain portions of the fastener 26 to preventapplication, brushing, spraying, electrostatic spraying, transferring,silk screen, and other similar methods and techniques. The scope of thisdisclosure does not depend upon the method used to apply the masticsealant to the fastener 26. The mastic sealant 11 applied to thefastener 26 may be any one of several readily available mastics sealantsand/or mastic-like products, such as silicone based sealants, elastomerbased sealants, coal tar and/or petroleum byproduct sealants, caulk-likesealants, epoxy sealants, and other similar products which retain arelatively resilient characteristic over time.

The fastener 26 shown in FIGS. 23-28 has a smooth shank 2, butalternatively could include a surface treatment, such as the ring-shapedprotrusions 25 shown in FIGS. 11-14. The fastener 26 may also include atwo-layer mastic sealant application like the two-layer mastic sealantdepicted in FIGS. 7 and 8. The applications and/or locations of themastic sealant 11 and/or the combination of the first sealant layer 12and the second sealant layer 13 are not dependent on whether thefastener 26 has a surface treatment feature applied on the shank 2.

Referring to FIGS. 29-31, the fastener 1 of FIGS. 4-6 is shown with asealing washer 27 assembled over the shank 2 of the fastener 1. Thesealing washer includes a top surface 28 that faces the undersidesurface 34 of the head 5 of the fastener 1 and a bottom surface 29opposite the top surface 28. One of the benefits of the sealing washer27 is that it provides a water tight connection as the sealing washer 27is pressed against and/or into the substrate 14 by the head 5 of thefastener 1 during installation. Mastic sealant 30 is applied to at leastone of the top and bottom surface 28, 29 of the sealing washer 27. Inmost industrial applications, it is preferred to apply the masticsealant 30 to both the top and bottom surfaces 28, 29 of the sealingwasher 27 so that the sealing washer 27 does not have to be assembled onthe fastener 1 in a specific orientation (i.e., with either the masticsealant 30 on the top surface or the bottom surface).

The mastic sealant 30 on the top surface 28 mates against the masticsealant 11 on the underside surface 34 of the head 5 when the sealingwasher 27 is assembled on the shank 2 of the fastener 1. The masticsealant 30 on the sealing washer 27 may or may not be similar and/or thesame material as the mastic sealant 11 on the fastener 1. The masticsealants 11, 30 are compatible, if not identical, so that a seal isformed between them. Excess combined mastic sealant 11, 30 is squeezedinto the gap 18 and onto the substrate 14 surfaces to form an improvedseal between the fastener 1, the sealing washer 27, and the substrate14. The combined mastic sealant 11, 30 will remain resilient andflexible over time regardless of formation and/or increasing contractionof the gap 18.

It is not necessary, but it is likely, that the thickness of the masticsealant 30 applied to the top and bottom surfaces 28, 29 of the sealingwasher 27 will be a similar thickness. However, the thickness of themastic sealant 30 that is applied to the top and bottom surfaces 28, 29of the sealing washer 27 will not necessarily be the same as thethickness of the mastic sealant 11 applied to the fastener 1. It shouldbe appreciated that the sealing washer 27 can be made of metal, plastic,fiber, or one of many other appropriate materials. The mastic sealant 30is applied to the sealing washer 27 using any one of the applicationmethods described above. It should also be appreciated that the sealingwasher 27 could alternatively be assembled with the fastener 26 shown inFIG. 24, for example.

Many modifications and variations of the present invention are possiblein light of the above teachings and may be practiced otherwise than asspecifically described while within the scope of the appended claims.These antecedent recitations should be interpreted to cover anycombination in which the inventive novelty exercises its utility. Withrespect to the methods set forth herein, the order of the steps maydepart from the order in which they appear without departing from thescope of the present disclosure and the appended method claims.Additionally, various steps of the method may be performed sequentiallyor simultaneously in time.

What is claimed is:
 1. A self-sealing fastener comprising: a shankextending longitudinally between a first end and a second end, the shankhaving an outer surface; a head extending radially outwardly from thefirst end of the shank, the head having an underside surface adjacent tothe first end of the shank and a topside surface opposite the undersidesurface; a mastic sealant for providing a water-tight seal afterinstallation of the self-sealing fastener disposed on the outer surfaceof the shank adjacent to: the first end of the shank, at least one ofthe second end of the shank and the underside surface of the head, or acombination thereof.
 2. The self-sealing fastener of in claim 1, whereinthe mastic sealant is disposed on the underside surface of the head. 3.The self-sealing fastener of in claim 2, wherein the head comprises anouter rim, wherein the underside surface of the head comprises a concaveportion defined by a trough that extends annularly about the first endof the shank and a flat radial portion that is positioned radiallybetween the concave portion and the outer rim, and wherein the masticsealant is disposed on the flat radial portion and the concave portionon the underside surface of the head.
 4. The self-sealing fastener of inclaim 2, wherein the shank has a shank diameter, wherein the shankcomprises a conical buttress at the first end, and wherein the shankdiameter progressively increases along the conical buttress movingtowards the head.
 5. The self-sealing fastener of in claim 4, whereinthe mastic sealant is disposed on the conical buttress of the shank. 6.The self-sealing fastener of in claim 1, wherein the mastic sealantcomprises a first sealant layer and a second sealant layer, wherein thefirst sealant layer directly contacts the outer surface of the shank,the underside surface of the head, or a combination thereof and whereinthe second sealant layer is disposed on the first sealant layer.
 7. Theself-sealing fastener of in claim 6, wherein the second sealant layereffective as a protective skin around the first sealant layer.
 8. Theself-sealing fastener of in claim 7, wherein the mastic sealant in thesecond sealant layer has a higher viscosity than the mastic sealant inthe first sealant layer.
 9. The self-sealing fastener of in claim 6,wherein the mastic sealant in the first sealant layer iscompensationally different from the mastic sealant in the second sealantlayer.
 10. The self-sealing fastener of in claim 6, wherein the masticsealant in the first sealant layer has a first sealant layer thicknessand the second sealant layer has a second sealant layer thickness thatequals 25 to 50 percent of the first sealant layer thickness.
 11. Theself-sealing fastener of in claim 1, wherein the mastic sealant is oneof a silicone-based sealant, an elastomer-based sealant, a caulk-basedsealant, an epoxy-based sealant, a petroleum byproduct sealant, coaltar, or a combination thereof.
 12. The self-sealing fastener of claim 1,wherein the shank comprises a threaded portion.
 13. The self-sealingfastener of claim 12, wherein the threaded portion is a helical threadedportion.
 14. The self-sealing fastener of claim 1, wherein a portion ofthe shank comprises a helical threaded portion.
 15. The self-sealingfastener of claim 14, wherein the mastic sealant is disposed on thehelical threaded portion.
 16. A self-sealing fastener comprising: ashank extending longitudinally between a first end and a second end, theshank having an outer surface and a threaded portion; a head extendingradially outwardly from the first end of the shank to an outer rim, thehead having an underside surface adjacent to the first end of the shankand a topside surface opposite the underside surface; the undersidesurface of the head including a concave surface defined by an annulartrough and a flat radial surface positioned radially between the concavesurface and the outer rim; and a mastic sealant disposed on the outersurface of the shank adjacent to the first end having a first thickness,the concave surface of the underside surface of the head having a secondthickness, and the flat radial surface of the underside surface of thehead having a third thickness.
 17. The self-sealing fastener of in claim16, wherein the first thickness of the mastic sealant, the secondthickness of the mastic sealant, and the third thickness of the masticsealant are equal.
 18. The self-sealing fastener of in claim 16, whereinthe second thickness of the mastic sealant is greater than the thirdthickness of the mastic sealant and wherein the third thickness of themastic sealant is greater than the first thickness of the masticsealant.
 19. The self-sealing fastener of in claim 16, wherein the firstthickness of the mastic sealant is greater than the second thickness ofthe mastic sealant and wherein the third thickness of the mastic sealantequals the second thickness of the mastic sealant.
 20. A method ofinstalling a self-sealing fastener in a substrate, the method comprisingthe steps of: applying a first layer of mastic sealant to the shank thatthat extends from an underside surface of a head and comprises athreaded portion, of the self-sealing fastener, the underside surface ofthe head of the self-sealing fastener, or a combination thereof;applying a second layer of mastic sealant over the first layer of masticsealant before the first layer of mastic sealant is fully cured suchthat the second layer of mastic sealant forms a protective skin over thefirst layer of mastic sealant, wherein a thickness of the second layerof mastic sealant is in a range of 25 to 50 percent of a thickness ofthe first layer of mastic sealant; curing the mastic sealant in thesecond sealant layer to a different degree than the mastic sealant inthe first sealant layer, wherein the mastic sealant in the secondsealant layer has a higher viscosity than the mastic sealant in thefirst sealant layer; and forcing the shank of the self-sealing fastenerinto the substrate wherein the second layer of mastic sealant rupturesas the second layer of mastic sealant makes contact with the substrateto flow the first layer of mastic sealant between the self-sealingfastener and the substrate and form a water-tight seal.